Microlens array, method of manufacturing the same, and optical device and electronic apparatus using the same

Abstract

A method of manufacturing a microlens array comprises the steps of providing a first light transmitting layer precursor above a master to form a first light transmitting layer; and providing a second light transmitting layer precursor above the first light transmitting layer to form a second light transmitting layer. The master comprises a plurality of first areas and a second area surrounding the first areas and having a lower affinity to the first light transmitting layer precursor than that of the first areas. The first light transmitting layer is formed above the first areas, but not above the second area.

What is claimed is:  
     
       1. A method of manufacturing a microlens array comprising: 
       providing a master;  
       defining first areas on said master with a first affinity to a first light transmitting layer precursor;  
       defining second areas on said master with a second affinity to said first light transmitting layer precursor, said second affinity being different from said first affinity;  
       providing said first light transmitting layer precursor above said master;  
       forming a first light transmitting layer above the first areas but not above the second areas with said first light transmitting layer precursor;  
       providing a second light transmitting layer precursor above the first light transmitting layer;  
       forming a second light transmitting layer over said second areas with said second light transmitting layer precursor.  
     
     
       2. The method of  claim 1  wherein the second light transmitting layer is also formed over said first light transmitting layer. 
     
     
       3. The method of  claim 1  wherein said second areas surround said first areas. 
     
     
       4. The method of  claim 1  wherein said second affinity is lower than said first affinity. 
     
     
       5. The method of  claim 1  wherein said first light transmitting layer precursor includes curved surfaces over said first areas. 
     
     
       6. The method of  claim 5  wherein said curved areas are formed by surface tension. 
     
     
       7. The method of  claim 1  wherein said first areas are circular. 
     
     
       8. The method of  claim 1  wherein said first areas are octagonal. 
     
     
       9. The method of  claim 1  wherein said second area repels said first light transmitting layer precursor during said step of providing said first light transmitting layer precursor above said master side that said first light transmitting layer is formed above said first areas, but not above said second area. 
     
     
       10. The method of  claim 1  wherein said light transmitting layer precursor is discretely applied to individual first areas during said step of providing said light transmitting layer precursor above said master. 
     
     
       11. The method of  claim 1  further comprising: 
       removing said first light transmitting layer and said second light transmitting layer from said master as a unit.  
     
     
       12. The method of  claim 11  further comprising: 
       removing said first light transmitting layer from said second light transmitting layer to expose a plurality of recesses in said second light transmitting layer.  
     
     
       13. The method of  claim 12  further comprising: 
       filling said recesses with a third light transmitting layer.  
     
     
       14. A method of manufacturing a microlens array comprising the steps of: 
       providing a first light transmitting layer precursor above a master to form a first light transmitting layer; and  
       providing a second light transmitting layer precursor above the first light transmitting layer to form a second light transmitting layer,  
       the master including a plurality of first areas and a second area surrounding the first areas, the second area having a different affinity to the first light transmitting layer precursor than that of the first areas, and  
       the first light transmitting layer being formed above the first areas, but not above the second area.  
     
     
       15. An electronic apparatus comprising an electro-optic device comprising a microlens array manufactured by the method according to  claim 14 . 
     
     
       16. A method of manufacturing an optical device comprising the steps of: 
       forming a microlens array by the process according to  claim 14 ; and combining the microlens array with a light source.  
     
     
       17. A method of manufacturing an optical device comprising the steps of: 
       forming a microlens array by the process according to  claim 14 ; and  
       combining the microlens array with imaging elements such that light focused by the microlens array enters the imaging elements.  
     
     
       18. A method of manufacturing a microlens array according to  claim 14 , the first light transmitting layer precursor having curved surfaces above the first areas formed by surface tension. 
     
     
       19. A method of manufacturing a microlens array according to  claim 14 , further comprising the step of curing the first light transmitting layer precursor and then providing the second light transmitting layer precursor above the first light transmitting layer. 
     
     
       20. A method of manufacturing a microlens array according to  claim 14 , the first areas being formed as circles. 
     
     
       21. A method of manufacturing a microlens array according to  claim 14 , each first area being formed as an octagon in which opposing sides have substantially the same lengths; adjoining sides have different lengths from each other; and the inner angles are substantially the same. 
     
     
       22. A method of manufacturing a microlens array according to  claim 14 , the first light transmitting layer precursor being provided above the first and second areas of the master, and being repelled from the second area to the first areas due to the low affinity of the second area to the first light transmitting layer precursor. 
     
     
       23. A method of manufacturing a microlens array according to  claim 14 , the first light transmitting layer precursor being provided individually in each first area. 
     
     
       24. A method of manufacturing a microlens array according to  claim 23 , a plurality of coloring materials being used as the first light transmitting layer precursor and being provided so that adjacent first areas have different colors. 
     
     
       25. A method of manufacturing a microlens array according to  claim 14 , wherein the first areas are formed in the surface of the master and the second area is formed with a film having a lower affinity to the first light transmitting layer precursor than that of the surface of the master. 
     
     
       26. A method of manufacturing a microlens array according to  claim 14 , further comprising the step of separating the first and second light transmitting layers from the master as a unit. 
     
     
       27. A method of manufacturing a microlens array according to  claim 26 , further comprising the steps of: 
       removing the first light transmitting layer from the second light transmitting layer to form recessed parts after the first and second light transmitting layers are separated from the master as a unit; and  
       filling the recessed parts with a third light transmitting layer precursor different from the first light transmitting layer precursor.  
     
     
       28. A method of manufacturing a microlens array according to  claim 27 , a plurality of coloring materials being used as the third light transmitting layer precursor. 
     
     
       29. An optical device comprising a microlens array manufactured by the method according to  claim 14 . 
     
     
       30. An optical device according to  claim 29 , further comprising a light source for emitting light to the microlens array. 
     
     
       31. An optical device according to  claim 29 , further comprising imaging elements which the light focused by the microlens array enters.